Post on 23-Nov-2021
Wind Turbine Gearbox Reliability Collaborative
Walt MusialNational Renewable Energy Laboratory
Golden, CO USAwalter_musial@nrel.gov
Albuquerque Marriott Pyramid North5151 San Francisco Road NEAlbuquerque, NM 87109 USA
Background• Wind Turbine Gearboxes do not meet their
design life.• Standards and improved industry practices have
helped but wind system costs are still rising. • Failures are not specific to one machine type or
application.• NREL’s 2.5 MW dynamometer has completed
most of the scheduled backlog.• NREL/DOE will address drivetrain reliability as a
significant new area for long term R&D.
Dynamometer Background/Specifications
• 2.5 MW rated power capacity -Power regeneration at 480 volts or 4160 volts.• Torque range 0 - 1.62 million N-m (13.5 million in-lb).• Speed range from 0 - 2250 RPM• 488 kN (110 kip) force capacity for dynamic shaft bending with servo-
hydraulic controls.• Fully automated SCADA torque/speed controls
Gear Reliability Collaborative Objectives
• Develop dynamometer testing capability to assess
gearbox/ drivetrain problems and solutions
• Understand how gearbox loads translate to bearing
response, stress, slip, and other gearbox problems.
• Develop a more comprehensive gearbox design load case
matrix.
• Evaluate and validate current drive train analytical tools.
Project Organizational Chart
NREL/DOE Dynamometer Test
Facility
Hal Link – Senior Test Engineer
Vahan Gevorgian – Electrical Instrumentation Engineer
Ed Overly – Lead Technician
Troy Boro – Mechanical Technician
Project TeamCoordinator
Dynamometer Test Resources
Test Article
Specialized Equipment
Expert Consultants
Instrumentation
Heavy Lifting Rental
Field Test
Drivetrain Analysis
Participants
Wind Turbine Gearbox Reliability Collaborative Organization
Field Test Team Dyno Test Team
Analysis Team
Project Management Team
Collaborative Advisory Committee
•Load cases•System loads•Internal loads
•Test plan•Test article•Test setup & execution•Data analysis
•Test plan•Test turbine•Test setup & execution•Data analysis
Public Data
Results
Proprietary and/or CRADA IP Protected
Data
Intellectual Property Protection
Participants shall not use their membership in the collaborative as a
means to promote or advance litigation against other participants
or potential participants.
• IP protection highest priority• Cooperative Research and development Agreements
(CRADA) can protect data brought in.• Data exchange among members will be limited as
needed.
Dynamometer Testing• Gearbox system instrumented to measure
strain, deflections, shaft displacements, and loads.
• Simulated field loading to replicate gearbox failures.
• Failure modes will be correlated with external loading.
• Root cause forensics
Dynamometer Test Envelope
Target Test Article– 600 to 900 kW Gearbox– Failures are
representative of currenfleet
– Cheaper– Failure database
established– 3X loading possible
0
500
1000
1500
2000
2500
3000
0 5 10 15 20 25 30 35RPM
Pow
er (k
W)
Rated Power Envelope
Test Platform Options• V-47 – 660-kW• NM -750 – 750 – kW• GE 1.5 kW bedplate with rebuilt Flender
gearbox. (default option)
Field Testing
• Drivetrain the same as dynamometer system.
• Tests will correlate damaging internal bearing loads with external loads.
• Forensic verification• Field test partners
wanted.
Gearbox Analysis• Provide modeling support to the testing
groups. • Use project field data or dynamometer test
data to model dynamometer test article response.
• Correlate Dyno response to turbine response.
• Use test data to gain confidence in codes.
Project Schedule
• Workshop was held at NREL July 11-12, 2006.• Draft plan distributed September 28, 2006• Comments, feedback, and commitments through
end of 2006. • Dynamometer testing to begin in early 2007
depending on commitments.• Annual reviews to determine project
continuation.
Project Teams Minimum Requirements
• Group with Common Purpose (preferable established working relationship)– Bearing Manufacturer– Turbine Manufacturer– Owner/Operator– Gearbox Manufacturer
• Articulated Problem• Benefits larger Industry with basic
conclusions• Example: Investigating response of SRB in
LS planets
Methods of Participation• Cash is always accepted.• In kind equipment • In-kind labor and support• Data, Data, Data (value negotiable)• Minimum thresholds of participation to
be determined.
Conclusions
• New collaborative to address gearbox reliability.
• Generic root causes to be addressed.• Confidentiality top priority• 20 year gearboxes???